HVAC systems for supermarkets: How to optimise energy efficiency?

Improving energy efficiency in HVAC systems for supermarkets and stores is vital, both within the facilities and during the transit of cold chain goods. These establishments consume a considerable amount of electricity, so implementing a centralised control hub at the store level is essential to achieve significant energy savings.

The current rise in online shopping has prompted many retailers to expand their warehouses and cold storage facilities and allocate more space in supermarkets to cater to the needs of transitioning customers. However, an important aspect is how HVACR technologies can enhance energy efficiency in supermarkets and minimise emissions.

Various factors influence the energy consumption of refrigeration systems in supermarkets. Typically, the air conditioning systems in supermarkets have a relatively small impact on overall power usage. 

However, HVAC and refrigeration equipment account for a significant portion, around 50 to 60 percent, of the total energy consumption in supermarkets and stores. Fortunately, advancements in technology have led to the achievement of high levels of energy efficiency. Additionally, combining heat pumps and air handling units has proven highly advantageous in developing eco-friendly solutions. Andrea Dalan, the Sensors Platform Manager at Carel Industries, emphasised the importance of incorporating energy recovery systems in supermarkets. This allows for the capture and utilisation of waste heat generated by storing goods, leading to more cost-effective HVAC systems.

Gaurav Bawa, Senior Vice President at WIKA India, suggests that a centralised approach to energy management is highly recommended as a comprehensive solution for supermarkets. Significant energy savings can be achieved by implementing a central control hub at the store level. This hub collects and exchanges data with various refrigeration controllers and heating systems. Energy recovery systems capture excess heat generated by supermarket refrigeration systems. The recovered heat can be repurposed to pre-heat water and warm different supermarket areas, reducing energy consumption.

Andrea Dalan emphasises prioritising energy-intensive food refrigeration systems over optimisation efforts. Manufacturers have introduced refrigerants with low global warming potential, specifically designed for commercial and industrial refrigeration in supermarkets. CO2-based central systems, such as CO2 racks with gas ejectors and advanced controls, can save approximately 12 percent of annual system energy consumption.

Stand-alone refrigeration units, which can be air-cooled or water-cooled, utilise hydrocarbons with low GWP. Connecting stand-alone systems to a central hub enhances efficiency by allowing individual equipment with varying loads to operate efficiently. Regarding transport, refrigeration equipment technologies employ cryogenic cooling, vacuum-insulated panels, and advanced temperature monitoring systems to ensure the safe transit and preservation of frozen and perishable goods. Temperature control and monitoring are crucial for transporting medicines, frozen meat, and flowers to supermarkets and stores, ensuring their freshness and usability.

Temperature monitoring during transport
Temperature monitoring systems enable accurate tracking, control, and regulation of product temperatures in various environments as vehicles traverse different temperature zones. Maintaining optimal HVAC conditions in vehicles like cars, flights, and trains ensures passenger comfort during journeys with the appropriate humidity and cool temperatures. However, when it comes to commercialising food products, particularly in countries like India with long distances and diverse product types, preserving the quality and freshness of perishable items presents a significant challenge. Therefore, temperature-measuring instruments and sensors are vital in the transportation industry.

The transportation industry relies on various sensor manufacturers that produce remote sensors connected to GPS. These sensors are specifically designed to monitor product conditions such as temperature and humidity, ensuring they are maintained within the appropriate ranges throughout the distribution process. Some sensors remain continuously connected through cellular technologies, while others store data for future access, offering flexibility in data management.

Temperature-measuring instruments have several advantages in transportation. Andrea highlights that the primary objective of temperature measurement during goods transportation is to ensure proper storage conditions, preventing spoilage or bacterial growth. To achieve this, it is essential to monitor and track the storage temperature of goods throughout the cold chain using data loggers. This guarantees that the goods remain suitable for consumption.

Monitoring temperature and humidity is particularly crucial in food transportation, as it greatly affects the proper preservation of goods. Additionally, the pharmaceutical sector requires even greater attention due to the potential for more extreme temperature conditions.

Continuous advancements are being made in refrigeration system efficiency, sensing, and controls, leading to improved performance and management of perishable goods. Supermarkets can benefit from these advancements by incorporating more efficient components and systems. Industrial Internet of Things (IIoT) solutions facilitate systems and processes by enabling conditional monitoring, alarming, asset tracking, predictive maintenance, and process optimisation. Therefore, personnel involved in HVAC systems need to operate within a robust IoT network that allows seamless data sharing for informed decision-making in the future. Also, engineers working with IoT-enabled HVAC equipment should possess comprehensive knowledge beyond the physical machinery, including cloud computing and remote monitoring, to analyse data and assess maintenance requirements. It is essential to ensure synchronised communication between all components, connecting them to a central hub. By leveraging smart HVACR devices and enhanced connectivity, along with skilled professionals, efficiencies in equipment and HVAC systems can be enhanced at all levels of stores and supermarkets.

 

Andrea Dalan, CAREL Sensors Platform Manager, Carel Industries.
The primary objective of measuring temperature and humidity is to ensure individual comfort or the ideal preservation and storage of goods in spaces.

Energy Efficiency and Renewable Energy (EERE), Department of Energy, Washington DC.
Refrigerants specifically designed for commercial and industrial refrigeration, for maximising performance in supermarket applications, have low global warming potential, aiming to minimise their impact on climate change.

Isha Sharma, Consultant, Cold Chain Logistics.
It is advisable to deploy cryogenic cooling, vacuum-insulated panels, and advanced temperature monitoring systems for safe transit and transport of frozen and perishable goods to supermarkets and stores.

Gaurav Bawa, Senior Vice President, WIKA India.
The variable refrigerant volume or variable refrigerant flow system is highly suitable for medium to large commercial areas as the systems employ refrigerant as the primary element for cooling and heating.